Simulation of Energy and Media Demand of Beverage Bottling Plants by Automatic Model Generation

Facing environmental challenges, high energy costs and a growing public awareness, the global brewing industry is increasingly publishing ambitious targets toward a more sustainable production. Small and medium-sized enterprises of the brewing and beverage industry cannot ensure energy and media efficiency mainly due to capital and knowledge inadequacy. This article addresses this problem and presents a pragmatic method to determine the energy and media demand. Accordingly, a modeling editor as well as a standardized data structure and automatic simulation parameter determination tools were developed to implement the method. A given production plant can be modeled with adequate details using the presented editor. Based on a configuration file, a holistic simulation model can be generated automatically in a simulation environment. A beverage bottling plant was studied, and the necessary datasets were obtained for implementing the proposed editor and, thereby, the method. It was confirmed that the simulated values of electrical energy and compressed air consumption match the measured empirical data. The measures to increase energy and media efficiency were also found effective. Using the presented method, enterprises of the brewing and beverage industry can easily uncover avenues for potential savings, test the effectiveness of optimization strategies, and substantiate possible investment decisions.